I finally started laser cutting the plastic pieces for the chassis.
I happened to have some orange 3mm acrylic and thought it would make a nice accent color.
Unlike the standard shell, mine is cut in three pieces and glued together. I had some worries that this wouldn’t be very strong but it turns out that the glued joint is extremely tough. With acrylic, we’re basically welding the pieces together. The solvent cement softens the plastic and the fused joint is incredibly tough. Even so, I reinforced it with a couple pieces I’d cut to calibrate the laser. These are just glued in underneath to add some thickness to the glued surface. I don’t know how durable it will be over time, especially flexing it from time to time to assemble, but so far, so good.